A light converter comprises: a solid-state optical member configured to absorb light of an excitation wavelength and generate light of an emission wavelength; a base; and a mechanical fastener attaching the solid-state optical member to the base. The light converter may be part of a light engine, a phosphor wheel or an automotive headlight. A method of manufacturing such a phosphor wheel is also provided.
Legal claims defining the scope of protection. Each claim is shown in both the original legal language and a plain English translation.
1. A light converter comprising: an annular solid-state optical member comprising a phosphor, the annular solid state optical member configured to absorb light of an excitation wavelength and generate light of an emission wavelength; a disk-shaped base; and a cover ring secured with the disk-shaped base and retaining the annular solid-state optical member by engaging an outer rim of the annular solid-state optical member; wherein no clamping force is applied to an inner rim of the optical converter.
This invention relates to a light converter designed for optical systems, particularly those requiring efficient and durable conversion of excitation light into emission light using a phosphor-based solid-state optical member. The problem addressed is the need for a robust, low-stress mounting solution for annular phosphor elements that avoids mechanical deformation or damage to the inner rim, which can degrade optical performance. The light converter includes an annular solid-state optical member containing a phosphor material. This member absorbs light at an excitation wavelength and emits light at a different wavelength. The optical member is secured within a housing formed by a disk-shaped base and a cover ring. The cover ring is fastened to the base and retains the optical member by engaging its outer rim, ensuring a stable position without applying any clamping force to the inner rim. This design prevents stress-induced deformation or cracking of the inner rim, which is critical for maintaining optical integrity and longevity. The absence of inner rim clamping also simplifies assembly and reduces manufacturing complexity. The overall structure ensures efficient light conversion while minimizing mechanical stress on the phosphor element.
2. The light converter of claim 1 wherein the annular solid state optical member comprises a plurality of color segments wherein the cover ring retains the color segments by engaging the outer rims of the color segment.
This invention relates to a light converter for modifying the color or spectral properties of light, particularly in applications such as automotive lighting or display systems. The problem addressed is the need for a compact, modular, and easily adjustable light converter that can produce multiple colors or color patterns without complex mechanical or electronic systems. The light converter includes an annular solid-state optical member, which is a ring-shaped structure made of one or more color segments. Each color segment is a discrete portion of the ring that emits or transmits light of a specific color or wavelength. The segments are arranged in a circular pattern to form the complete ring. The color segments are retained in place by a cover ring that engages the outer rims of each segment, ensuring proper alignment and stability. The cover ring may be designed to allow individual segments to be replaced or adjusted, enabling customization of the color output. The segments may be made of materials such as phosphors, quantum dots, or other wavelength-converting materials, depending on the application. The overall design allows for precise control over the color distribution and intensity of the emitted light, making it suitable for applications requiring dynamic or multi-color lighting effects.
3. The light converter of claim 2 wherein the cover ring does not engage the inner rims of the color segments.
Technical Summary: This invention relates to a light converter designed for use in optical systems, particularly in applications requiring precise color mixing or light modulation. The problem addressed is the need for a durable, efficient light converter that minimizes mechanical wear and maintains optical performance over time. The light converter includes a cover ring and multiple color segments arranged around a central axis. Each color segment has an inner rim and an outer rim, with the outer rim being secured to the cover ring. The cover ring does not engage the inner rims of the color segments, allowing them to move independently. This design prevents mechanical interference between the cover ring and the inner rims, reducing friction and wear while ensuring smooth rotation or adjustment of the color segments. The color segments may be arranged in a circular or segmented pattern, and the cover ring may be fixed or adjustable to control the position of the segments. The light converter may further include a base structure supporting the color segments and cover ring, with alignment features to maintain precise positioning. The color segments can be made of materials that selectively transmit, reflect, or filter light, enabling dynamic color mixing or modulation. The invention is particularly useful in projection systems, displays, or lighting applications where color accuracy and longevity are critical. By eliminating contact between the cover ring and the inner rims, the design enhances reliability and optical consistency.
4. The light converter of claim 1 wherein the cover ring does not engage the inner rim of the annular solid-state optical member.
The invention relates to a light converter designed to improve optical performance in lighting systems. The device addresses the problem of inefficient light distribution and heat dissipation in solid-state lighting, particularly in systems using annular (ring-shaped) optical members. Traditional designs often suffer from misalignment, thermal stress, or uneven light output due to mechanical constraints between components. The light converter includes an annular solid-state optical member, such as a phosphor or wavelength-conversion element, which modifies the spectral properties of incident light. A cover ring is positioned around the optical member to protect it and enhance structural integrity. Unlike conventional designs, the cover ring does not engage the inner rim of the optical member, preventing mechanical stress that could lead to misalignment or cracking. This non-engaging configuration allows for thermal expansion without distortion, improving durability and optical stability. The optical member may be supported by a base structure that ensures proper alignment while minimizing contact points to reduce thermal resistance. The cover ring may also include features to enhance heat dissipation or light extraction efficiency. The overall design ensures uniform light output and prolonged operational life in high-power lighting applications.
5. The light converter of claim 1 wherein the outer rim of the annular solid-state optical member is disposed between the disk-shaped base and the cover ring.
This invention relates to a light converter designed to improve the efficiency and durability of solid-state lighting systems, particularly those using annular (ring-shaped) optical members. The problem addressed is the need for better heat dissipation and structural integrity in such devices, which are often used in high-power LED applications where thermal management is critical. The light converter includes an annular solid-state optical member, such as a phosphor or wavelength-converting material, which is mounted between a disk-shaped base and a cover ring. The outer rim of the optical member is positioned between these two components, ensuring secure containment and thermal contact. The base and cover ring are designed to provide mechanical support while also facilitating heat transfer away from the optical member. The optical member itself may be a phosphor layer or a composite structure that converts incident light (e.g., from an LED) into a different wavelength, such as white light from blue LED excitation. The arrangement ensures that the optical member is protected from environmental factors while maintaining efficient thermal dissipation. The base and cover ring may be made of thermally conductive materials, such as metals or ceramics, to further enhance heat management. This design is particularly useful in high-power lighting applications where thermal stress and mechanical stability are concerns. The invention improves upon prior art by providing a more robust and thermally efficient structure for solid-state optical components.
6. The light converter of claim 1 , wherein the annular solid-state optical member is configured to absorb blue light and generate at least one of yellow light and green light.
This invention relates to a light converter for use in optical systems, particularly for converting blue light into other wavelengths. The problem addressed is the need for efficient and compact light conversion in applications such as lighting, displays, or optical communication, where converting blue light into broader spectrum light (e.g., yellow or green) is desirable. The light converter includes an annular solid-state optical member, which is a ring-shaped structure made of a material capable of absorbing blue light and emitting light of different wavelengths. This optical member is designed to absorb incident blue light and generate at least one of yellow light or green light in response. The conversion process relies on the optical properties of the solid-state material, which may involve photoluminescence or other wavelength-shifting mechanisms. The annular shape of the optical member allows for efficient light coupling and distribution, ensuring that the converted light is emitted in a controlled manner. The invention may be integrated into larger optical systems, such as light-emitting diodes (LEDs) or laser-based devices, where blue light is initially generated and then converted to produce a desired output spectrum. The design aims to improve color rendering, energy efficiency, or spectral purity in optical applications.
7. The light converter of claim 1 , wherein the annular solid-state optical member comprises an annular ceramic phosphor member.
The invention relates to light converters used in lighting systems, particularly those involving solid-state light sources such as LEDs. The problem addressed is the need for efficient and durable light conversion materials that can withstand high temperatures and provide uniform light output. Traditional phosphor materials may degrade over time or fail to provide consistent color conversion. The light converter includes an annular (ring-shaped) solid-state optical member designed to convert light from a primary light source, such as an LED, into a different wavelength. This optical member is specifically an annular ceramic phosphor member, which offers advantages in thermal stability and mechanical robustness compared to conventional phosphor materials. Ceramic phosphors are less prone to degradation under high-intensity light and heat, ensuring long-term performance. The annular shape allows for efficient light coupling with the primary light source, optimizing light conversion and minimizing losses. The ceramic phosphor member may be integrated into a lighting fixture or module, where it surrounds the primary light source to convert its emitted light into a desired color or spectrum. This design is particularly useful in applications requiring high brightness and color stability, such as automotive lighting, display backlights, or general illumination. The use of ceramic phosphors enhances durability and reliability, making the light converter suitable for demanding environments.
8. The light converter of claim 1 , wherein the disk-shaped base includes a central opening.
A light converter is designed to modify the properties of light, such as its wavelength, intensity, or direction, for applications in lighting, displays, or optical systems. The device includes a disk-shaped base that supports one or more optical elements, such as phosphors, filters, or diffusers, to alter the light passing through or reflecting off it. The base may also include a central opening, which allows for the integration of additional components, such as light sources or sensors, or enables the passage of light through the center of the device. This opening can improve heat dissipation, reduce weight, or facilitate mechanical mounting. The optical elements may be arranged in layers or patterns to achieve specific light conversion effects, such as color mixing, beam shaping, or spectral filtering. The disk-shaped design ensures uniform light distribution and efficient heat management, making it suitable for high-power applications. The central opening enhances flexibility in system integration, allowing for compact and modular optical setups. This design is particularly useful in LED lighting, projection systems, and other optical devices where precise light control and thermal management are critical.
9. A phosphor wheel comprising: the light converter of claim 1 ; and a motor arranged to rotate the disk-shaped base around an axis passing through the disk-shaped base and normal to a planar surface of the annular solid-state optical member.
A phosphor wheel is used in projection display systems to convert excitation light, such as blue or ultraviolet light, into broader-spectrum light, typically for generating white light in laser-based projectors. The challenge is to efficiently convert the excitation light while maintaining mechanical stability and thermal management during high-speed rotation. The phosphor wheel includes a disk-shaped base and a motor that rotates the base around an axis perpendicular to its planar surface. The wheel incorporates a solid-state optical member, which is an annular (ring-shaped) structure attached to the base. This optical member contains a phosphor material that absorbs excitation light and re-emits it at longer wavelengths, producing the desired color output. The motor ensures continuous rotation of the wheel, allowing the phosphor material to be exposed to the excitation light in a controlled manner, preventing overheating and ensuring uniform light conversion. The design optimizes light conversion efficiency by maximizing the surface area of the phosphor material exposed to the excitation light while maintaining structural integrity during rotation. The motor's alignment with the axis ensures smooth operation and precise positioning of the optical member relative to the excitation light source. This configuration is particularly useful in high-performance projection systems where reliability and thermal management are critical.
10. The light converter of claim 1 wherein no adhesive secures the annular solid-state optical member to the disk-shaped base.
This invention relates to a light converter designed for optical systems, addressing the challenge of securely mounting a solid-state optical component without using adhesives, which can degrade over time or introduce optical distortions. The device consists of a disk-shaped base and an annular solid-state optical member, such as a phosphor or wavelength-converting element, positioned on the base. The optical member is mechanically secured to the base through a friction fit or interference fit, eliminating the need for adhesives. The base may include a raised annular rim or a stepped surface to align and retain the optical member in place. The optical member is designed to convert incident light, such as blue or ultraviolet light, into a different wavelength, such as white light, for applications in lighting or display systems. The adhesive-free design ensures long-term stability, reduces manufacturing complexity, and avoids potential optical degradation caused by adhesive outgassing or curing. The invention is particularly useful in high-power or high-reliability optical systems where adhesive failure could compromise performance.
11. A light converter comprising: an annular solid-state optical member comprising a phosphor, the annular solid state optical member configured to absorb light of an excitation wavelength and generate light of an emission wavelength; a disk-shaped base; and a cover ring secured with the disk-shaped base and retaining the annular solid-state optical member by engaging an outer rim of the annular solid-state optical member; wherein the cover ring is secured with the disk-shaped base by plugs projecting from one of an outer flank of the disk-shaped base and the cover ring mated with corresponding notches of the other of the outer flank of the disk-shaped base and the cover ring.
A light converter is designed to convert light from an excitation wavelength to an emission wavelength using a phosphor-containing solid-state optical member. The device addresses challenges in efficiently converting and directing light in optical systems, particularly where precise alignment and secure retention of optical components are required. The converter includes an annular solid-state optical member that absorbs excitation light and emits light at a different wavelength. This member is retained between a disk-shaped base and a cover ring, which engages the outer rim of the optical member to hold it in place. The cover ring is secured to the disk-shaped base using a plug-and-notch mechanism, where plugs projecting from either the outer flank of the base or the cover ring mate with corresponding notches in the other component. This design ensures stable positioning of the optical member while allowing for easy assembly and disassembly. The annular shape of the optical member facilitates uniform light conversion and distribution, making the device suitable for applications in lighting, displays, or optical sensors where controlled light emission is critical. The secure retention mechanism prevents misalignment or damage to the optical member during operation.
12. A phosphor wheel comprising: an annular ceramic phosphor member; a disk-shaped base; and a cover ring secured with the disk-shaped base and retaining the annular ceramic phosphor member by engaging an outer rim of the annular ceramic phosphor member; wherein the cover ring is secured with the disk-shaped base by plugs projecting from one of an outer flank of the disk-shaped base and the cover ring mated with corresponding notches of the other of the outer flank of the disk-shaped base and the cover ring.
This invention relates to phosphor wheels used in projection systems, particularly addressing durability and assembly challenges in high-power lighting applications. The phosphor wheel includes an annular ceramic phosphor member that converts excitation light into visible light. The wheel is constructed with a disk-shaped base and a cover ring that secures the phosphor member by engaging its outer rim. The cover ring is fastened to the disk-shaped base using a plug-and-notch mechanism, where plugs on either the base or the cover ring mate with corresponding notches on the other component. This design ensures stable retention of the phosphor member while simplifying assembly and disassembly. The ceramic phosphor member provides high thermal resistance, crucial for maintaining performance under intense illumination. The cover ring's engagement with the outer rim of the phosphor member prevents lateral movement, enhancing structural integrity. The plug-and-notch fastening method allows for precise alignment and secure attachment without additional fasteners, reducing mechanical stress and potential failure points. This configuration improves durability and reliability in high-power projection systems.
13. The phosphor wheel of claim 12 wherein the outer rim of the annular ceramic phosphor member is disposed between the disk-shaped base and the cover ring.
A phosphor wheel for use in projection systems includes an annular ceramic phosphor member with an outer rim positioned between a disk-shaped base and a cover ring. The phosphor wheel is designed to convert excitation light, such as blue or ultraviolet light, into visible light for display applications. The ceramic phosphor member is supported by the base and protected by the cover ring, which helps maintain structural integrity and thermal stability during operation. The arrangement ensures efficient heat dissipation and prevents deformation or damage to the phosphor material under high-intensity light exposure. The cover ring may also serve as a reflective or protective barrier, enhancing light output and longevity. This design addresses challenges in phosphor-based projection systems, such as heat management and mechanical durability, by integrating the phosphor member within a robust, thermally conductive structure. The wheel's configuration allows for precise alignment and stable rotation, ensuring consistent light conversion performance. The ceramic material of the phosphor member provides high thermal resistance and chemical stability, making it suitable for prolonged use in high-power lighting and display systems. The overall structure minimizes optical losses and mechanical stress, improving efficiency and reliability in projection applications.
14. The phosphor wheel of claim 12 , wherein the annular ceramic phosphor member is configured to absorb blue light and generate at least one of yellow light and green light.
A phosphor wheel for use in light projection systems, particularly in solid-state lighting applications, addresses the challenge of efficiently converting blue light into broader spectrum light for improved color rendering. The wheel includes an annular ceramic phosphor member that absorbs blue light and emits at least one of yellow light or green light. This conversion process enhances the color output of the system by expanding the spectral range beyond the narrow blue emission of the light source. The ceramic material provides durability and thermal stability, ensuring consistent performance under high-intensity illumination. The phosphor wheel is designed to rotate, allowing for dynamic control of light output and color temperature. The annular shape optimizes light absorption and emission efficiency, while the ceramic composition resists degradation from prolonged exposure to high-energy light. This technology is particularly useful in applications requiring high-brightness, high-color-fidelity lighting, such as projectors, automotive headlights, and display systems. The phosphor wheel's ability to convert blue light into broader spectrum light improves energy efficiency and color accuracy, addressing limitations in traditional lighting solutions.
15. The phosphor wheel of claim 12 wherein the disk-shaped base is configured for connection with a motor for rotating the disk-shaped base around an axis passing through the disk-shaped base and normal to a planar surface of the annular ceramic phosphor member by a threaded adapter or a central opening of the disk-shaped base.
A phosphor wheel is a component used in projection systems, particularly in solid-state lighting and display applications, to convert excitation light into broader spectrum light. A common challenge is efficiently coupling the phosphor wheel to a motor for rotation while maintaining structural integrity and thermal management. The invention addresses this by providing a phosphor wheel with a disk-shaped base that can be connected to a motor in two distinct ways. The base is designed to rotate around an axis perpendicular to its planar surface, ensuring stable and precise rotation. The first connection method involves a threaded adapter, which allows for secure and adjustable attachment to the motor shaft. The second method uses a central opening in the base, providing a direct and simple connection. The phosphor wheel includes an annular ceramic phosphor member, which is mounted on the base and converts excitation light into the desired output spectrum. The ceramic material provides durability and efficient heat dissipation, critical for maintaining performance and longevity in high-power applications. The design ensures reliable mechanical coupling while optimizing thermal and optical performance.
16. The phosphor wheel of claim 12 further comprising: a motor connected with the disk-shaped base for rotating the disk-shaped base around an axis passing through the disk-shaped base and normal to a planar surface of the annular ceramic phosphor member.
This invention relates to phosphor wheels used in projection systems, particularly addressing the need for efficient and durable phosphor excitation in light sources. The phosphor wheel includes a disk-shaped base supporting an annular ceramic phosphor member, which is excited by a light source to produce converted light for projection. The wheel rotates to distribute heat and prevent degradation of the phosphor material. The motor is connected to the disk-shaped base to rotate it around an axis perpendicular to the planar surface of the phosphor member. This rotation ensures uniform excitation and cooling, extending the lifespan of the phosphor material. The motor may be integrated into the base or coupled externally, depending on design constraints. The system may also include additional components like heat sinks or reflective surfaces to enhance performance. The invention improves upon existing phosphor wheels by providing a more reliable and efficient mechanism for rotating the phosphor material, reducing thermal stress and improving light output consistency. This is particularly useful in high-power projection systems where thermal management is critical. The motor-driven rotation ensures even excitation and cooling, addressing common issues in prior art designs where uneven heating leads to phosphor degradation.
17. The phosphor wheel of claim 12 wherein the annular ceramic phosphor member comprises a plurality of color segments wherein the cover ring retains the color segments by engaging the outer rims of the color segments.
A phosphor wheel is used in projection systems to convert excitation light into different colors for display. Traditional phosphor wheels often suffer from issues such as heat dissipation, mechanical stability, and color uniformity. This invention addresses these problems by providing a phosphor wheel with an annular ceramic phosphor member that includes multiple color segments. The color segments are retained in place by a cover ring that engages the outer rims of the segments. The ceramic material improves heat resistance and durability, while the segmented design allows for precise color control. The cover ring ensures structural integrity by securely holding the segments at their outer edges, preventing misalignment or damage during high-speed rotation. This design enhances thermal management, mechanical stability, and color consistency, making it suitable for high-performance projection systems. The phosphor wheel may also include features such as a hub for mounting, a reflective surface for light conversion, and cooling mechanisms to further improve efficiency. The segmented approach allows for modular assembly, enabling customization of color segments based on specific display requirements.
18. The phosphor wheel of claim 17 wherein the cover ring does not engage the inner rims of the color segments.
A phosphor wheel is a component used in projection systems, particularly in solid-state lighting and display applications, to convert excitation light into broader spectrum light. A common issue with phosphor wheels is maintaining structural integrity and alignment of color segments while allowing efficient heat dissipation. The invention addresses this by incorporating a cover ring that does not engage the inner rims of the color segments. The phosphor wheel includes a hub, a plurality of color segments arranged around the hub, and a cover ring that secures the color segments to the hub. The cover ring is designed to avoid direct contact with the inner rims of the color segments, reducing mechanical stress and potential misalignment. This design allows the color segments to expand and contract thermally without interference, improving durability and performance. The cover ring may be secured to the hub using fasteners or other attachment mechanisms, ensuring stability while minimizing constraints on the color segments. The invention enhances the reliability and longevity of phosphor wheels in high-power lighting and projection systems.
19. A projector for generating color sequential illumination, the projector comprising: the phosphor wheel of claim 17 ; and a light source arranged to apply exciting light to the annular ceramic phosphor member.
A projector generates color sequential illumination by using a phosphor wheel and a light source. The phosphor wheel includes an annular ceramic phosphor member with a reflective surface and a phosphor layer on the reflective surface. The phosphor layer is made of a ceramic material containing a phosphor and a binder, where the binder is a ceramic material that is the same as or different from the phosphor. The phosphor layer is formed by sintering a mixture of the phosphor and the binder. The light source applies exciting light to the annular ceramic phosphor member, causing the phosphor to emit light of a desired color. The reflective surface enhances light output efficiency by reflecting emitted light toward the projector's optical system. The ceramic construction of the phosphor wheel provides durability and thermal stability, ensuring consistent performance over time. This design allows for efficient color sequential illumination, where different colors are generated in rapid succession by rotating the phosphor wheel and exciting different sections with the light source. The projector is suitable for applications requiring high brightness and color accuracy, such as digital cinema, large-venue displays, and high-end home theater systems.
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October 29, 2018
November 12, 2019
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